Insulated commercial sectional door with extruded spacers

ABSTRACT

An improved insulated door panel having an outer and inner spaced apart skins and an internal foam core includes a first spacer disposed between a top end of the outer skin and a top end of the inner skin and a second spacer disposed between a bottom end of the outer skin and a bottom end of the inner skin. The first and second spacers include first and second protrusions, respectively, on an inner face of the first and second spacers. The first and second protrusions secure the first and second spacers to the foam core.

BACKGROUND

Doors of the type used for closing a large opening in a building, suchas a garage door, have long been manufactured using a plurality ofsubstantially identical panels. The plurality of panels are typicallyhingedly or pivotally connected together to permit relative hingingmovement between adjacent panels when the door is moved between a closedvertical position in which the panels are aligned, an intermediateposition in which the panels are hinged at an angle to each other, andan open horizontal position.

Such multi-panel doors are commonly referred to as sectional doors andoften employ thin sheet material, such as metal, fiberglass, or plastic,and an insulating core to form each panel of the multi-panel door. Thus,the individual panels are light in weight and highly warp-resistant overrelatively long spans of time. However, due to the compositeconstruction of such panels, multi-panel doors often lack sufficientstructural strength and/or do not provide sufficient thermal andelectrical insulation between adjacent panels, and between the door andthe outside environment.

SUMMARY

In a first aspect, there is provided an improved insulated door panelhaving first and second spaced apart skins, an internal foam core andfirst and second spacers. The first spacer is disposed between a top endof the outer skin and a top end of the inner skin and the second spaceris disposed between a bottom end of the outer skin and a bottom end ofthe inner skin. The first spacer includes a first protrusion on an innersurface of the first spacer and the second spacer includes a secondprotrusion on an inner surface of the second spacer. The firstprotrusion secures the first spacer to the foam core and the secondprotrusion secures the second spacer to the foam core.

In certain embodiments, the first and second protrusions include a ledgeto further secure the first and second protrusions to the foam core.

In other embodiments, the first and second protrusions are texturized toincrease the surface area of the first and second protrusions thatcontacts the foam core.

In yet another embodiment, the first and second spacers each includethree protrusions.

In still another embodiment, an outer surface of the first spacerincludes a tongue and an outer surface of the second spacer includes agroove that corresponds to the tongue.

In some embodiments, the first spacer and the second spacer includelateral recesses to provide a friction fit with bent portions of theouter and inner skins.

In an additional embodiment, the first and second spacers are sized tomaintain a distance between the outer skin and the inner skin. Inanother embodiment, the first and second spacers are sized to maintain adistance of up to about three inches between an exterior surface of theouter skin and an exterior surface of the inner skin.

In a second aspect, there is described a continuous, automated method ofmanufacturing insulated door panels that includes placing a first spaceradjacent to a top end of an inner skin and placing a second spaceradjacent to a bottom end of the inner skin. The first spacer includes afirst inner protrusion and the second spacer includes a second innerprotrusion. The method includes injecting a foamable liquid between theinner skin, the first spacer and the second spacer and placing an outerskin so that a top end of the outer skin is adjacent to the first spacerand a bottom end of the outer skin is adjacent to the second spacer. Themethod also includes allowing the foam to cure so that the firstprotrusion and the second protrusion are held within the cured foam tohold the first spacer and the second spacer in position with respect tothe outer and inner skins.

In certain embodiments, allowing the foam to cure so that the firstprotrusion and the second protrusion are held within the cured foamincludes securing a ledge of the first and second protrusions within thecured foam.

In other embodiments, the method also includes conveying the outer skin,the inner skin, the first spacer and the second spacer to a foamingstation where the foamable liquid is injected.

In yet another embodiment, the method includes unrolling the firstspacer from a first roller.

In still another embodiment, the method includes unrolling the secondspacer from a second roller.

In some embodiments, the method includes aligning the first spacer andthe second spacer so that they are perpendicular to the inner skin.

In another embodiment, the method includes locating the first spacer andthe second spacer between the outer skin and the inner skin to maintaina predetermined distance between an exterior surface of the outer skinand an exterior surface of the inner skin.

In certain embodiments, the predetermined distance is between about 1and about 4 inches.

In some embodiments, the method includes passing the first spacer, thesecond spacer, the inner skin, and the outer skin through an adjustablepressure conveyor.

In other embodiments, the adjustable pressure conveyor can acceptdifferent sizes of the first spacer and second spacer to create a panelof different thicknesses.

In certain embodiments, the method includes changing the distancebetween the inner skin and the outer skin by providing a third spacerand a fourth spacer that are different in size than the first spacer andthe second spacer.

In other embodiments, the method includes thermally insulating the outerskin from the inner skin by locating the first spacer and the secondspacer between the outer skin and the inner skin.

In yet another embodiment, the method includes electrically insulatingthe outer skin from the inner skin by locating the first spacer and thesecond spacer between the outer skin and the inner skin.

In still another embodiment, the method includes securing the firstspacer and the second spacer to the inner skin using an adhesive.

In some embodiments, the adhesive is a pressure sensitive adhesive.

In a third aspect, there is described an insulated, sectional door thatincludes a first panel including a first spacer and a second panelincluding a second spacer. The second panel is hingedly coupled to thefirst panel to permit movement of the first panel and the second panelwith respect to each other from an aligned position to an angledposition. The first spacer includes a spacer tongue and the secondspacer includes a spacer groove that corresponds in shape to the spacertongue so that when the first and second panels are in the alignedposition the spacer tongue fits within the spacer groove to seal thefirst panel to the second panel.

In certain embodiments, the first and second spacers maintain a distancebetween the first and second panels when the first and second panels arein the aligned position.

In other embodiments, the first spacer and the second spacer thermallyinsulate the first panel from the second panel when the first and secondpanels are in the aligned position.

In yet another embodiment, the first spacer and the second spacerelectrically insulate the first panel from the second panel when thefirst and second panels are in the aligned position.

In still another embodiment, the first panel includes a tongue and thesecond panel includes a groove and the tongue is aligned with the groovewhen the first and second panels are in the aligned position.

In some embodiments, the tongue is spaced from the groove when the firstpanel and the second panel are in the aligned position.

Other aspects, features, and advantages will become apparent from thefollowing detailed description when taken in conjunction with theaccompanying drawings, which are a part of this disclosure and whichillustrate, by way of example, principles of the inventions disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a garage door having four door panels;

FIG. 2 is a cross section view of an upper panel that is hingedlycoupled to a lower panel;

FIG. 3 is a close-up cross section view of the panels of FIG. 2;

FIG. 4 is a further magnified, close-up cross sectional view of thepanels of FIG. 2; and

FIG. 5 is a schematic perspective view of a continuous, automated methodof manufacturing insulated door panels.

DETAILED DESCRIPTION

In the description which follows, like parts are marked throughout thespecification and drawings with the same reference numerals,respectively. The drawings are not necessarily to scale and certainfeatures may be shown exaggerated in scale or in somewhat schematic formin the interest of clarity and conciseness.

Referring initially to FIG. 1, an overhead sectional door 100 enclosesan opening in a building 102 defined by two jambs 104 and 106 and aheader 108. A driveway 110 forms a lower edge of the opening. The door100 includes four panels 112 that are hingedly connected to each otherand mounted on conventional track and rollers (not shown) within thebuilding 102 to enable the movement of the door 100 between the verticalposition shown and a horizontal (i.e., overhead) position. In otherembodiments, the door 100 may include any number of panels 112 and maybe located in any suitable opening.

Referring now to FIG. 2, a lower door panel 114, which is the lowestdoor panel of the door 100, and an upper door panel 116 are shown. Thelower door panel 114 is hingedly coupled to the upper door panel 116 ata hinge 118 to allow the lower door panel 114 and the upper door panel116 to pivot with respect to each other from the aligned position (shownin FIG. 2) to an angled position (not shown) as the door moves from theclosed position (shown in FIG. 1) to an open/horizontal position (notshown). The lower door panel 114 and the upper door panel 116 eachinclude an outer skin 120, an inner skin 122, a foam core 124 disposedbetween the outer skin 120 and the inner skin 122, a first spacer 126and a second spacer 128. Additional panels may be connected to the upperdoor panel 116, as shown in FIG. 1.

Referring again to FIG. 2, the outer and inner skins 120 and 122 formthe external surfaces of the lower and upper door panels 114 and 116 andcontain a foam core 124 therebetween. The outer and inner skins 120 and122 may include a substantially planar face or may includeornamentation, such as one or more raised-panel features. Referring nowto FIG. 3, the skins 120 and 122 may also include bent portions 132 and133 near the top 135 and 134 and bottom 137 and 136 of the outer andinner skins 120 and 122, respectively, to allow for attachment of thefirst and second spacers 126 and 128 to the outer and inner skins 120and 122, as will be described in more detail below. In some embodiments,the skins 120 and 122 do not include bent portions 132 and 133.

Referring again to FIG. 2, each panel 114 and 116 includes a firstspacer 126 and a second spacer 128 disposed between the outer skin 120and the inner skin 122 to thermally and electrically insulate the outerskin 120 from the inner skin 122. The spacers 126 and 128 also separatethe outer skin 120 from the inner skin 122 to give the desired overallthickness to the lower and upper panels 114 and 116. For example, insome embodiments, the spacers 126 and 128 are sized to maintain adistance of about three inches between an exterior surface 130 of theouter skin 120 and an exterior surface 131 of the inner skin 122 tocreate a panel 114 or 116 that is approximately three inches thick. Inother embodiments, the spacers 126 and 128 may be sized to create apanel 114 or 116 that is thicker or thinner than three inches.

The first and second spacers 126 and 128 also thermally and electricallyinsulate the lower door panel 114 from the upper door panel 116 when thelower door panel 114 and the upper door panel 116 are in the alignedposition, as shown in FIG. 2. The first and second spacers 126 and 128contact each other and maintain a distance between the lower door panel114 and the upper door panel 116 to further insulate the lower doorpanel 114 from the upper door panel 116 while sealing the space betweenthe lower door panel 114 and the upper door panel 116. The first andsecond spacers 126 and 128 seal the space between the lower door panel114 and the upper door panel 116 to prevent entry of water, air and/orlight between the lower door panel 114 and the upper door panel 116 whenthe lower door panel 114 and the upper door panel 116 are in the alignedposition. The first and second spacers 126 and 128 also seal to eachother to prevent entry of water, air and/or light between the first andsecond spacers 126 and 128 when the lower door panel 114 and the upperdoor panel 116 are in the aligned position. Thus, in some embodiments,the distance between the lower door panel 114 and the upper door panel116 is filled by and sealed by the first and second spacers 126 and 128when the door panels 114 and 116 are in the aligned position.

Referring now to FIG. 3, the inner skin 122 includes a tongue 138positioned on the top 134 of the inner skin 122 and a groove 140positioned on the bottom 136 of the inner skin 122. The tongue 138corresponds in shape to the groove 140 so that the tongue 138 fitswithin the groove 140 when the lower and upper door panels 114 and 116are in the aligned position. The tongue 138 and groove 140 help toprevent the passage of water and contaminants between the lower doorpanel 114 and the upper door panel 116. In some embodiments, the surfaceof the tongue 138 does not contact the surface of the groove 140 whenthe lower door panel 114 and the upper door panel 116 are in the alignedposition to prevent the transfer of thermal and/or electrical energybetween the lower and upper door panels 114 and 116 by way of the tongue138 and groove 140, as shown in FIG. 3. While the tongue 138 and groove140 are located between the spacers 126 and 128 and the hinge 118 inFIGS. 2 and 3, the tongue 138 and groove 140 may be located at anysuitable location, for example, between the spacers 126 and 128 and theexterior surface 130 of the outer skin 120.

In some embodiments, the inner skin 122 includes a first rabbet (notshown) positioned on the top 134 of the inner skin 122 and a secondrabbet (not shown) positioned on the bottom 136 of the inner skin. Thefirst rabbet corresponds in shape to the second rabbet so that the firstand second rabbets form a shiplap joint when the lower and upper doorpanels 114 and 116 are in the aligned position. In other embodiments,the lower and upper door panels 114 and 116 may form any suitable jointwhen in the aligned position, such as, for example, a butt joint or ananti-pinch joint.

Referring now to FIG. 4, the first spacer 126 includes a spacer tongue146 on an outer surface 148 of the first spacer 126 and the secondspacer 128 includes a spacer groove 152 on an outer surface 150 of thesecond spacer 128 that corresponds in shape to the spacer tongue 146.Similar to the tongue 138 and groove 140 shown in FIG. 3, the spacertongue 146 and spacer groove 152 help prevent passage of water andcontaminants between the lower panel 114 and the upper panel 116.However, unlike the tongue 138 and groove 140 shown in FIG. 3, in someembodiments the spacer tongue 146 contacts the spacer groove 152 and maycompress against the spacer groove 152 to seal the lower door panel 114to the upper door panel 116 to prevent passage of water, light and airbetween the first spacer 126 and the second spacer 128. In theembodiment of FIG. 4, the spacer tongue 146 is in the shape of atruncated triangle and the spacer groove 152 is in a correspondingshape. In other embodiments, the spacer tongue 146 and the spacer groove152 may be any suitable shape, such as, for example, a roundedtriangular shape similar to the tongue 138 and groove 140 shown in FIG.3. In some embodiments, the first and second spacers 126 and 128 includea different joint, such as, for example, a shiplap joint, a butt joint,an anti-pinch joint, or another suitable joint.

The first spacer 126 and the second spacer 128 also include protrusions154 on inner surfaces 149 and 151 of the spacers 126 and 128,respectively. In some embodiments, the protrusions 154 help to securethe spacers 126 and 128 to the foam core 124 and thereby secure thespacers 126 and 128 to the door panel 114 or 116. The spacers 126 and128 may include any number of protrusions 154 and the protrusions 154may be any suitable shape and size. In the embodiment shown in FIG. 4,for example, some of the protrusions 154 include a ledge 156 thatextends perpendicularly from the protrusion 154. A volume of the foamcore 124 is located between the ledge 156 and the inner surface 149 or151 of the spacer 126 or 128 to further secure the spacer 126 or 128 tothe foam core 124. In other embodiments, the protrusions 154 may becurved in shape and may include one or more prongs, hooks or otherfeatures to further secure the spacers 126 and 128 to the foam core 124.In some embodiments, the protrusions 154, as well as the inner surfaces149 and 151, may include texturization 174 such as, for example, smallridges and grooves, to increase the surface area of the spacers 126 and128 that comes into contact with the foam core 124.

In some embodiments, the spacers 126 and 128 also include lateral steps158 that extend inwardly from lateral sides of the spacers 126 and 128.The lateral steps 158 correspond in shape to bent portions 132 and 133of the outer and inner skins 120 and 122, respectively, so that afriction fit exists between the lateral steps 158 and the bent portions132 and 133 to help secure the spacers 126 and 128 in the correctposition with respect to the outer and inner skins 120 and 122 and toimprove the structural integrity of the lower and upper door panels 114and 116. As such, a first corner 162 and 163 and second corner 164 and165 of the bent portions 132 and 133 correspond to the first and secondcorners 166 and 168, respectively, of the lateral steps 158. Inaddition, ends 170 and 171 of the skins 120 and 122 contact a thirdcorner 172 of the lateral steps 158 to further hold the spacers 126 and128 in place with respect to the skins 120 and 122. In otherembodiments, the lateral steps 158 and the bent portions 132 and 133 mayhave any suitable shape and need not be in the specific configurationsshown in FIG. 4.

The first and second spacers 126 and 128 may be constructed of anysuitable material and are preferably constructed of a material that canbe compressed, is resilient and flexible, and is a thermal and/orelectrical insulator. In some embodiments, for example, the spacers 126and 128 are made of polyvinyl chloride (PVC) and/or ethylene propylenediene monomer (EPDM).

Referring now to FIG. 5, a continuous, automated method of manufacturinginsulated door panels 112 is shown schematically. A outer skin 120 issupplied in a continuous fashion from a roller (not shown) or some othercontinuous feed, such as, for example, a series of panels that arelinked together at a flexible joints, as described in U.S. Pat. No.4,746,383 entitled “Continuous Foamed-in-place Door Panel ManufacturingProcess,” which is hereby expressly incorporated by reference. An innerskin 122 is also supplied in a continuous fashion from a roller (notshown) or some other continuous feed. The outer skin 120 and/or theinner skin 122 may pass through one or more forming stations, such as,for example, an embossing station, a stamping station, or a roll formstation. The outer skin 120 is aligned over the inner skin 122, and theouter and inner skins 120 and 122 are fed toward a foaming station 178.

A first spacer 126 and a second spacer 128 are also supplied in acontinuous fashion from rollers 180 and 182, respectively, toward thefoaming station 178. As described above, the spacers 126 and 128 aremade of a flexible, resilient material, such as PVC, that may be rolled,stored, and then continuously feed from the rollers 180 and 182. Thefirst and second spacers 126 and 128 are unrolled from rollers 180 and182, respectively, and the first spacer 126 is placed adjacent to thetop 134 of the inner skin 122 and the second spacer 128 is placedadjacent to a bottom end 136 of the inner skin 122 such that the innersurfaces 149 and 151 (FIG. 4) of the first and second spacers 126 and128, which include the protrusions 154, face a center of the inner skin122. In some embodiments, the first and second spacers 126 and 128 aresecured to the inner skin 122 by an adhesive (not shown), such as, forexample, a pressure sensitive adhesive. In some embodiments, the spacers126 and 128 are arranged so that they are perpendicular to the innerskin 122.

The outer skin 120, inner skin 122, first spacer 126 and second spacer128 are conveyed to the foaming station 178 where a foamable liquid 184is injected between the inner skin 122, the first spacer 126 and thesecond spacer 128, as shown schematically in FIG. 5. The outer skin 120is then aligned with the inner skin 122 and placed so that the top 135of the outer skin 120 is adjacent to the first spacer 126 and the bottom137 of the outer skin 120 is adjacent to the second spacer 128. As such,the first spacer 126 and the second spacer 128 maintain a predetermineddistance between the outer and inner skins 120 and 122, which may be,for example, between about 1 inch and about 4 inches. Any distance maybe maintained by the spacers 126 and 128 between the outer and innerskins 120 and 122. The foamable liquid 184 is then allowed to cure toform the foam core 124 (FIG. 4) as the outer skin 120, inner skin 122,first spacer 126 and second spacer 128 pass through a pressure conveyor192. The protrusions 154, which protrude into the volume of foamableliquid 184, are secured within the foam core 124 when the foamableliquid 184 solidifies to form the foam core 124. In some embodiments,the ledges 156 and/or surface texture 174 on the protrusions 154 (FIG.4) further secure the protrusions 154 to the foam core 124 as thefoamable liquid 184 cures.

In some embodiments, the pressure conveyor 192 is adjustable such thatthe pressure conveyor 192 can be adjusted to form panels 112 ofdifferent thicknesses using first and second spacers 126 and 128 ofdifferent heights. For example, in some embodiments, a distance betweenthe top rollers 194 and the bottom rollers 196 of the pressure conveyor192 can be adjusted to accommodate first and second spacers 126 and 128of different heights, thus creating panels 112 of different heights. Inone embodiment, for example, the pressure conveyor 192 may be adjustedto produce a thicker panel 112 by increasing the distance between thetop rollers 194 and the bottom rollers 196. In one embodiment, thepressure conveyor 192 may be adjusted to produce a thinner panel 112 bydecreasing the distance between the top rollers 194 and the bottomrollers 196.

In some embodiments, spacers 126 and 128 of different heights can beused to create panels 112 of different sizes without modifying the outerskin 120 and inner skin 122. Referring to FIG. 2, for example, toincrease the thickness of the door 100, taller first spacers 126 andtaller second spacers 128 are located between the outer skin 120 and theinner skin 122. To decrease the thickness of the door 100, shorter firstspacers 126 and shorter second spacers 128 are located between the outerskin 120 and the inner skin 122. Thus, referring again to FIG. 5, toincrease the thickness of the panel 112 that is produced, the spacers126 and 128 are replaced with larger spacers 126 and 128 and thepressure conveyor 192 is adjusted so that the distance between the toprollers 194 and the bottom rollers 196 of the pressure conveyor 192 isgreater. To decrease the thickness of the panel 112 that is produced,the spacers 126 and 128 are replaced with smaller spacers 126 and 128and the pressure conveyor 192 is adjusted so that the distance betweenthe top rollers 194 and the bottom rollers 196 is smaller. Changing thespacers 126 and 128 and adjusting the pressure conveyor 192 can be donequickly and thus manufacturing downtime to allow for changes in panel112 thickness may be minimized. In addition, since the thickness of thepanel 112 can be adjusted without changing the design and/or themanufacturing process of the outer skin 120 and the inner skin 122, insome embodiments, tooling associated with the outer skin 120 and theinner skin 122 need not be adjusted and/or replaced in order to changethe thickness of the panel 112 that is produced. This may also decreasethe cost and time associated with changing the thickness of the panel112.

In some embodiments, the method of manufacturing door panels alsoincludes securing a first bulb seal 186 (FIG. 2) to a bottom end 188 ofthe lower door panel 114. The first bulb seal 186 is located on thebottom end 188 of the lowest panel of an insulated door 100 to provide asealing surface between the door 100 and the driveway 110, as shown inFIG. 1. Referring again to FIG. 2, in some embodiments the method mayalso include securing a second bulb seal 190 within the first bulb seal186 so that if the first bulb seal 186 is damaged or otherwise removed,the second bulb seal 190 will continue to seal to the driveway 110. Thefirst and second bulbs seals 186 and 190 may be made of any suitablematerial and in some embodiments are made of a durable,thermally-insulating material such as PVC or EPDM.

In the foregoing description of certain embodiments, specificterminology has been resorted to for the sake of clarity. However, thedisclosure is not intended to be limited to the specific terms soselected, and it is to be understood that each specific term includesother technical equivalents which operate in a similar manner toaccomplish a similar technical purpose. Terms such as “outer” and“inner,” “upper” and “lower,” “first” and “second,” “internal” and“external,” “above” and “below” and the like are used as words ofconvenience to provide reference points and are not to be construed aslimiting terms.

In addition, the foregoing describes only some embodiments of theinvention(s), and alterations, modifications, additions and/or changescan be made thereto without departing from the scope and spirit of thedisclosed embodiments, the embodiments being illustrative and notrestrictive.

Also, the various embodiments described above may be implemented inconjunction with other embodiments, e.g., aspects of one embodiment maybe combined with aspects of another embodiment to realize yet otherembodiments. Further, each independent feature or component of any givenassembly may constitute an additional embodiment.

What is claimed is:
 1. An insulated, sectional door, comprising: a firstpanel including a first spacer disposed between an outer skin and aninner skin, wherein the first spacer includes a first protrusion on aninner surface of the first spacer; a second panel pivotally coupled tothe first panel and including a second spacer disposed between an outerskin and an inner skin, wherein the second spacer includes a secondprotrusion on an inner surface of the second spacer; wherein the firstprotrusion extends into and secures the first spacer to a first foamcore sandwiched between the outer and inner skins of the first panel andthe second protrusion extends into and secures the second spacer to asecond foam core sandwiched between the outer and inner skins of thesecond panel; and wherein the first spacer and the second spacer includelateral steps that correspond in shape to and engage with bent portionsextending from the outer and inner skins of the first and second panelsto secure the first and second spacers to the first and second panels;and wherein at least a portion of the foam core is disposed between thelateral steps and the outer and inner skins of the first and secondpanels to separate the first and second spacers from outer and innerskins of the first and second panels.
 2. The insulated, sectional doorof claim 1, wherein the first and second protrusions include a ledge tofurther secure the first and second protrusions to the first and secondfoam cores, respectively.
 3. The insulated, sectional door of claim 1,wherein a surface of the first and second protrusions includes a textureto increase the surface area of the first and second protrusions thatcontacts the first and second foam cores, respectively.
 4. Theinsulated, sectional door of claim 1, wherein the first and secondspacers each include three protrusions.
 5. The insulated, sectional doorof claim 1, wherein an outer surface of the first spacer includes atongue and an outer surface of the second spacer includes a groove thatcorresponds to the tongue.
 6. The insulated, sectional door of claim 5,wherein the inner skin of the first panel further comprises a secondgroove and the inner skin of the second panel further comprises a secondtongue; the second groove and the second tongue forming a secondbarrier, along with the groove and tongue in the first and secondspacers, to prevent contaminants moving through the first and the secondpanels when the insulated, sectional door is in a closed position. 7.The insulated, sectional door of claim 1, wherein the lateral steps ofthe first spacer and the second spacer frictionally engage with the bentportions of outer and inner skins of the first and second panels.
 8. Theinsulated, sectional door of claim 1, wherein the first and secondspacers are sized to maintain a distance of about three inches betweenthe outer skin and the inner skin of the first and second panels.
 9. Theinsulated, sectional door of claim 1, wherein the bent portionscomprising at least four right angles to provide at least three contactsurface areas between each of the outer and inner skins of the first andsecond panels and the respective first or second spacer.
 10. Theinsulated, sectional door of claim 1, wherein the inner skin of thefirst panel further comprises a groove and the inner skin of the secondpanel further comprises a tongue; the groove and the tongue forming abarrier against contaminants moving from and into the first and thesecond spacers.
 11. The insulated, sectional door of claim 1, whereinthe second panel is pivotally coupled to the first panel via a hingefastened onto the inner skins of first and second panels.
 12. Aninsulated, sectional door, comprising: a first panel including a firstspacer that extends into a first foam core sandwiched between a firstset of inner and outer skins; a second panel including a second spacerthat extends into a second foam core sandwiched between a second set ofinner and outer skins, wherein the second panel is pivotally coupled tothe first panel to permit movement of the first panel and the secondpanel with respect to each other from an aligned position to an angledposition; wherein the first spacer includes a spacer tongue and thesecond spacer includes a spacer groove that corresponds in shape to thespacer tongue so that when the first and second panels are in thealigned position the spacer tongue fits within the spacer groove to sealthe first panel to the second panel; wherein the first spacer and thesecond spacer include lateral steps to engage with correspondinglyshaped bent portions extending from respective first and second sets ofouter and inner skins; and wherein at least a portion of the foam coreis disposed between the lateral steps and first and second sets of theouter and inner skins to separate the first and second spacers fromfirst and second sets of outer and inner skins.
 13. The insulated,sectional door of claim 12, wherein the first and second spacersmaintain a distance between the first and second panels when the firstand second panels are in the aligned position.
 14. The insulated,sectional door of claim 12, wherein the first spacer and the secondspacer thermally insulate the first panel from the second panel when thefirst and second panels are in the aligned position.
 15. The insulated,sectional door of claim 12, wherein the first spacer and the secondspacer electrically insulate the first panel from the second panel whenthe first and second panels are in the aligned position.
 16. Theinsulated, sectional door of claim 12, wherein the first panel includesa tongue and the second panel includes a groove, wherein the tongue isaligned with the groove when the first and second panels are in thealigned position.
 17. The insulated, sectional door of claim 16, whereinthe tongue is spaced from the groove when the first panel and the secondpanel are in the aligned position.
 18. The insulated, sectional door ofclaim 12, wherein the bent portions comprising at least four rightangles to provide at least three contact surface areas between each ofthe first and second sets of outer and inner skins and the respectivefirst or second spacer.